Autotech 10.109.418K Sport 16V Camshaft Set, Mk1, Mk2, Mk3 16V - Manual (Page 2)

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2. (cont)
Note: because the timing mark on the vibration damper and the "0" on the flywheel can
indicate TDC for either cylinder No 1 or No 4, don't use these marks for double-checking
here. Use the mark on the camshaft only.
3. Pull all four spark plug wires off the plugs. Keep the wires attached to the distributor cap,
and remove the cap from the distributor.
4. Remove the upper intake manifold plenum. To do this, first remove the two rear support
braces ( 20 Nm/15 ft lb)., all vacuum hoses, electrical connections, the throttle cable, and
the intake boot from the throttle body. Then, using a 13mm wrench, remove the 5 nuts
that hold the upper plenum to the lower (
20 Nm/15 ft lb). Slide the upper plenum off of
the lower half.
5. Cover the lower manifold to prevent any dirt or objects from falling into the engine.
6. Loosen the belt tensioner using a 15mm wrench. Slide the timing belt off of the cam
sprocket.
7. Using a scribe or indelible pen, mark the position of the ignition distributor body relative to
the cylinderhead. This will aid in re-installation and closer initial timing settings. Remove the
two bolts that retain the ignition distributor to the head. Remove the distributor and set
aside.
8. Remove the two center and six outer valve cover bolts. Remove the valve cover. If the rubber
gasket has gotten hard or brittle, replace it. Otherwise, set the gasket aside for re-use.
9. With the engine still at TDC, use a clean rag to wipe the oil off of the two chainwheels and
the top portion of the timing chain. Using a "paint pen" or marker, mark the position of the
chain and chainwheels relative to one another (two places). This will aid in the proper timing
of the new cams later (arrows, Fig 2).
10. Removing the cam bearing caps - Use an 11mm wrench to:
• remove bearing caps 5 and 7 (each cap is marked) from the INTAKE camshaft.
• Next, remove the end cap on the INTAKE cam closest to the chainwheel.
• Remove caps 1 and 3 on the EXHAUST cam, then remove the two end caps as well.
• Now gradually and evenly loosen the nuts on the remaining caps a little at a time, so the
tension in the valve springs and cam chain are released evenly.
NOTE THE DIRECTION AND NUMERICAL SEQUENCE OF THE BEARING CAPS ON THE ENGINE!
IF THESE CAPS ARE INSTALLED INCORRECTLY, IT CAN PREVENT THE CAMSHAFTS FROM
TURNING AND WILL CAUSE UNREPAIRABLE CAMSHAFT AND BEARING WEAR!
11. Lift the camshafts from the head TOGETHER, then remove the drive chain. Make sure you
have marked the chain and chainwheels, as in Figure 2, before separating them!
(cont)
Fig 2